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HVAC Module Assembly: Installation

WARNING: This page is about a different car, the 2002 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the HVAC module assembly to the vehicle. See Fig 6. Connect the temperature actuator electrical connector. Connect the blower motor resistor electrical connector. Connect the blower motor electrical connector.
  2. Install the wiring harness clips to the HVAC module assembly bracket. Install the daytime running lights sensor wiring harness clip from the HVAC module assembly. Connect the I/P lamp dimmer switch electrical connector.
  3. Connect the vacuum supply hose to the vacuum tank. Install the air distribution duct. Install the floor air duct to the HVAC module. Install the cross vehicle beam to the front of the dash. See Fig 5. Install the nuts and bolts for the cross vehicle beam. Tighten the nut and bolts to specification. See TORQUE SPECIFICATIONS .
  4. Install the steering column mounting brace bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Install HVAC duct work to the cross vehicle beam. Install the body control module to the cross vehicle beam. Connect the wiring harness to the cross vehicle beam.
  5. Install the bolt retaining the cross vehicle beam to the HVAC module. Tighten the bolt retaining the cross vehicle beam to the HVAC module to specification. Install the instrument panel carrier to the cross vehicle beam.
  6. Tighten the steering column brace bolts behind the under hood electrical center for the steering column brace. Tighten the bolts to specification. Install the under hood electrical center. Install the air cleaner assembly to the vehicle.
  7. Raise the vehicle. Install the nut for the HVAC module assembly bracket. See Fig 4. Tighten the nut to specification. Install the heater case plate and the seals for the heater pipes. Install the nuts holding the heater case plate for the heater pipes. See Fig 3.
  8. Install the heater case plate and seal for the evaporator block. Install the nuts holding the heater case plate for the evaporator block. Tighten the nuts to specification. Install the drain tube elbow to the evaporator block heater case plate. See Fig 2.
  9. Install the evaporator hose to the evaporator. Install the outlet heater hoses to the heater core. See Fig 1. Install the inlet heater hose to the heater core. Lower the vehicle. Connect the negative battery cable. Fill the engine cooling system. Recharge the A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
Fig 1: Removing, Installing & Positioning Heater Hose
G00192076Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Evaporator Drain Tube
G00189620Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Heater Case Plate
G00189621Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing HVAC Bracket
G00189623Courtesy of GENERAL MOTORS CORP.
Fig 5: Removing & Installing Cross Vehicle Beam
G00189624Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing & Installing HVAC Module
G00189625Courtesy of GENERAL MOTORS CORP.
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